ELCOS CEM-380 Instruction Manual

1
ELCOS SRL - Parma - EN - CEM-380 /1
PANEL FOR CONTROL AND PROTECTION OF IRRIGATION
MOTOR PUMPSET
TYPE CEM-380
Complete with electronic transmitter (electronic pressure switch) and digital pressure gauge for pump water
pressure.
85,50
2,5m
Ø6,5
33
210 172
10062
Fixing system
With two or
three
clamps
On request
with vibration
dampers tted
on the top
part of the
control unit
DIMENSIONS
INSTRUCTION AND USER MANUAL
PROTECTS THE MOTOR PUMP GROUP SET BY
THEM IN THE EVENT OF:
• low oil pressure
• over-temperature
• belt breakage
• minimum fuel level
• available A1
• A2 (low diesel pressure)
• low coolant level
• insufcient pump water pressure
• pump water overpressure
It is equipped with display
to the following functions:
- pump protection exclusion
- battery and oil lights
- protections intervention
- hour-meter
- timer
- pump water pressure
gauge
- fuel level indicator
- tachometer
- battery voltmeter
Assembly on the
machine and in
the open air.
182
96
113,50

ELCOS SRL - Parma - EN - CEM-380 /1
2
MOTOR PUMP START
- OFF
- MANUAL STOP
- RESET
- UNIT POWER SUPPLY
- GLOW PLUGS CONTROL
- ENGINE PUMP START UP
BRIEF INSTRUCTIONS
TECHNICAL DATA
Battery voltage supply 12 Vdc 24 Vdc
Voltage supply 8 ÷ 32V
Circuit loading with key at zero 0 mA
Tachometer Max 4000 RPM precision ± 10 RPM
Timer 1 ÷ 96h
Instruments precision: battery voltmeter, fuel level gauge 2%
Hour-meter 5 digit
Max load of the outputs:
• starting motor (black)
• stopping (yellow)
• preheating (white/brown)
• lighthouse (brown)
• general alarm (red/green)
40A
3A
3A
3A
3A
Pump water pressure gauge 0 ÷ 21 bar
Pump water pressure transmitter:
• Maximum permissible pressure
• With pressure 4 ÷ 14 bar
• With pressure 1 ÷ 4 bar
21 bar
differential 2 bar
differential 1 bar
Degree of protection:
Box front
rear
Connector
IP54
IP23
IP20
Installation conditions for external use
Temperature range -20 ÷ +60°C
Weight 1000 g
Anomaly A2
(insufcient diesel
pressure).
Stoppage due to high
engine temperature
Engine protections are
active.
Stoppage due to low
engine oil pressure.
The battery is
not charging.
Stoppage due to lack of
battery charging
(belt brekage).
Stoppage due to low
engine oil pressure.
Press to select the displayed function,
each time it is pressed, the instrument
indicated by the display changes.
Hold down to silence the general
alarm (buzzer).
Pump water pressure
is regular.
Pump protection excluded
Pump protection active.
Stoppage due to low
pump water pressure.
Press to adjust electro-
nic pump water pressure
switch.
Press until the 2 signs start
ashing to exclude pump
protection to re-activate.
Protection, press again until they
switch off.
AUT.
START
Display
Stoppage due to low
coolant level.
Press if you want to
set working time
( up to 96 hours).
Stop for end
of work time.
Shows the timer
(if set). General fault A1
tripped.
Stoppage due to low
fuel level.

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ELCOS SRL - Parma - EN - CEM-380 /1
The engine protections are enabled when the ENGINE PROTECTIONS ACTIVE light comes on, (20 se-
conds after the end of starting impulse and however 1 minute after positioning the key on “AUT”).
Interventions of the protection probes (fitted on the engine), indicated by the relevant lights, stop the engi-
ne, they are memorised and can be split into two groups:
- OIL PRESSURE SWITCH - A1 ANOMALY PRESENT
- A2 (LOW FUEL PRESSURE)
- OVERTEMPERATURE - BATTERY CHARGING ALTERNATOR
SWITCH ( BELT BREAKAGE)
- FUEL LEVEL SWITCH
- flashing signal: 20% fuel reserve
(T) (WITHOUT ENGINE STOP)
- Signal always on: stop for minimum fuel level (W)
- PROBE FOR COOLANT LEVEL
The pump protection is enabled when warning lights PUMP PROTECTION ACTIVE come on after the water pressure has
remained stable for 2 consecutive minutes, in any case 10 minutes after the engine started. Intervention of the protection
(5 seconds after the pressure goes up or down by two bars) stops the engine and is shown on the display:
OPERATION
SETTING ELECTRONIC PRESSURE SWITCH ADJUSTMENT (TRANSMITTER) WATER PUMP
Lit up with key on “AUT”, they switch of f with the engine running
and regular oil pressure and battery charge system.
OIL AND BATTERY INDICATOR LIGHTS
TIMER
PUMP PROTECTION EXCLUSION
(ENABLED ONLY WITH ENGINE RUNNING)
OVERPRESSURE remains set to two bars, this value is added to
the working pressure
(for example, working pressure 9 bars overpressure 11 bars)
PUMP PROTECTION
NO ADJUSTING IS REQUIRED.
or
Insufcient water
pump pressure
(subpressure)
INSUFFICIENT WATER
PRESSURE
OVERPRESSURE
Pump water
WORK. PRESS. 10
SUBPRESSURE. 08
However it is possible to change the two bars of pressure
lowering (subpressure), by pressing button .
This change is deleted, when the engine is stopped.
Press to set the
SUBPRESSURE
value
Press to select the
WORKING PRES-
SURE
The push-button excludes pump protection:
exclusion is obtained by keeping it pressed for at least 3 consecutive seconds; the function is indicated by the two
intermittent lights,
This exclusion is cancelled by pressing the push-button again or by turning the start key onto “ZERO”.
Immediate for: Delayed by 5 seconds for:
ENGINE PROTECTIONS
Check the system pressure by replacing the traditional pressure switch.
Enabled with key on “AUT”, it makes it possible, if necessary, to have the motor pump work for an adjustable length
of time (maximum 96 hours), at the end of which it stops and the WORK TIME OVER sign lights up on the display.
The work time is set by pressing the push-button ( lights up) until the desired value appears on the
DISPLAY . On releasing the push-button, the timer automatically starts working, continously di-
splaying the remaining work time.
CANCELLING THE SET TIME
To zeroing the set time there are two methods: -keep the push-button pressed until it reaches zero or
- by turning the starter key onto “ZERO” (the engine pump will stop).

ELCOS SRL - Parma - EN - CEM-380 /1
4
The control unit comprises ve instruments selectables in sequence by pressing the button
HOUR-METER -Total hours of operation (with the engine running the signal :
pulsates to indicate the correct functioning of the HOUR-METER.
PRESSURE GAUGE - Pressure water pump
TACHOMETER - Speed of motor pump
FUEL LEVEL INDICATOR - Fuel level percentage
VOLTMETER - Battery voltage
OPERATION
Is activated with key in AUT the display shows the phrase .
The duration of the preheating action can be set.
Is indicated on the display when the action has ceased .
This can be obtained by fitting on the outside an optical and/or acoustic signaller to be
connected to the RED/GREEN wire. It is activated on protection intervention.
The control unit shut down the engine in three conditions:
- turning the starter key onto “ZERO”.
- protection intervention.
- timer intervention at the end of the work period.
The unit adapts to two different stop system:
- by working the ELECTROMAGNET for 20 seconds which pulls the STOP lever.
- by cutting off power to the SOLENOIDVALVEshutting off the flow of fuel.
The pump protection is enabled with the switching on of the ACTIVE PUMP
PROTECTION (after 2 consecutive minutes of stable water pressure, indicated by the
visual signal REGULAR PUMP PRESSURE and in any case, 10 minutes after the start
of the motor pump).
The intervention of the protection (5 seconds after the increase or decrease of the pres-
sure) stops the engine and is indicated by the visual signal for LOW PUMP WATER-
PRESSURE or WATERPUMPOVERPRESSURE .
GLOW PLUGS PREHEATING
fAcTORY-ExcLUDED
GENERAL ALARM
STOPPING THE ENGINE PUMP
PUMP PROTECTION
GLOW PLUGS
PREHEATING
ENGINE
STARTING
INSTRUMENT
The emergency stop can be actived in all working conditions, by mounting one or more
click-down push-button. On the display it’s reported
EMERGENCY
STOP .
Turning the key to the AUT position stops the electronic pressure gauge.
Control is activated 1 minute after the completion of the starting pulse.
Intervention is highlighted by the relevant indicators
WATER TRANSMIT-
TER STOPPED flashing warning light
and stops the motor pump after 2 seconds.
To exclude intervention, press the push-button PUMP PROTECTION EXCLUSION.
EMERGENcY STOP
ON REQUEST fUNcTION
cONTROLLING THE cONNEcTION Of THE PUMP WATER
ELEcTRONIc PRESSURE GAUGE (TRANSMITTER)
RESET : is obtained by turning the start key onto “ZERO”.
}
ON REQUEST

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ELCOS SRL - Parma - EN - CEM-380 /1
ATTENTION
FOR LOADS WITH
HIGHER ABSORP-
TION 3A IT IS
ESSENTIAL TO PUT
A RELAY
FUSES SUBSTITUTION
THE FUSES ARE INSIDE THE
CONTROL UNIT. TO ACCESS THE
INSIDE REMOVE THE FRONT
PANEL BY UNSCREWING THE
FOUR SCREWS. REPLACE WITH
A FUSE OF THE SAME VALUE.
FROM 15/54 OF
START KEY;
USABLE FOR
HEADLIGHT AND
OTHERS
A1 GENERIC
ANOMALY
A2
INSUFFICIENT
DIESEL
PRESSURE
INSULATE
POSSIBLE
CABLES NOT
CONNECTED
If the function - LOW
COOLING LIQUID LEVEL is
not used: connect
YELLOW/ORANGE WIRE to
earth .
YELLOW/
ORANGE
CONNECTOR A CONNECTOR B
CONNECTOR C
ACCESSORIES ON REQUEST
(2/7) ELECTROMAGNET OR ELECTRO-VALVE
(4) THERMOSTATIC SWITCH
(15) WATER PUMP PRESSURE SWITCH
(16) FUEL FLOAT
(155) RADIATOR LIQUID LEVEL PROBE
(173) PUMP WATER PRESSURE TRANSMITTER
(SUPPLIED)
ELECTROMAGNET :activates the engine stop
lever.
SOLENOID : to close the fuel.
To stop with SOLENOID cut and insulate
the BLUE/BROWN lead.
MOUNTED ON ENGINE
(3) OIL PRESSURE SWITCH
(26/28)PERMANENT MAGNETS CHARGE
ALTERNATOR OR PRE-EXCITATION
CHARGE ALTERNATOR
(27) ALTERNATOR REGULATOR
(40) STARTING MOTOR
(41) BATTERY
(106)GLOW PLUGS
(157)VISUAL INDICATOR (GENERAL ALARM)
RED/
GREEN
3AMAX
BATTERY
RED
PRE-EXCITATION
CHARGE BATTERY ALTERNATOR:
WHITE/RED
GREEN
BROWN
DO NOT USE
3A MAX
3AMAX
BLACK (40A MAX)
+ BATTERY
ORANGE /YELLOW
WHITE/BROWN
ORANGE/BLUE
ORANGE
BROWN (ONLY PERM. MAGN.)
YELLOW WHITE
SKY BLUE
BLACK/BLUE
CABLE 2,5m
GREY
GREEN
PERMANENTS MAGNETS
YELLOW
YELLOW
RED
BROWN
GREEN
+ BATTERY
WHITE/RED
EXCITED IN DRIVE
EXCITED IN STOP MODE
STOP SYSTEM ARRANGEMENT
The control panel is arranged to command
stop withELECTROMAGNET
COOLANT LEVEL PROBE
FOR RADIATORS WITH
PLASTIC EXPANSION TANK
SCREW
ELECTRODE
ROD
ELECTRODES
FOR RADIATORS WITH
METAL EXPANSION TANK
WHITE/RED
3A MAX
ORANGE/BROWN
WIRING DIAGRAM
BLUE/BROWN
Connector
ELIMINATE THE BRIDGE WHEN CONNECTING
THE EMERGENCY BUTTON
EMERGENCY
STOP
This can be
obtained with a
latching button
on releasing the
emergency
button, starting
or motion of the
engine is
stopped.
To reset, release
the button, and
place the start
key onto ZERO.
BROWN
BLACK

ELCOS SRL - Parma - EN - CEM-380 /1
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PRESS TO DISPLAY THE
REQUIRED PROGRAMMING
ACCESS TO PROGRAMMING MODE.
Turn the key to
DO NOT SET IN RUNNING
Press (5”) at the same time to DISPLAY
USER
PROGRAMMING
EXIT FROM PROGRAMMING MODE.
Re-position the key to zero
LANGUAGE
CHOICE
USER
PROGRAMMING
TACHOMETER
SETTING
Start with the ignition key
and bring the
engine to idle at constant
known speed for example
via a portable tachometer.
LANGUAGE CHOICE. The language set up in the factory is ITALIAN; the languages that
can be selected are: ENGLISH - FRENCH - GERMAN - SPANISH and PORTUGUESE.
700 RPM 1500 RPM
LANGUAGE CHOICE
ENGLISH
LANGUAGE CHOICE
ENGLISH
Press to select language
Press until you get the right
indication on the display
Press and wait for
PROGRAMMED to be
written.
USER PROGRAMMING AND TACHOMETER SETTING
Dispalyed on the
dispalay
Example
Press and wait for
PROGRAMMED to be
written.

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ELCOS SRL - Parma - EN - CEM-380 /1
YOUR ELECTRICAL TECHNICIAN CAN ASK US ANYTHING ABOUT THIS CONTROL
UNIT BY TELEPHONING ONE OF OUR TECHNICIANS
Only for starting and surveillance of the diesel motor pump and stops it if there are anomalies in
the parts controlled by probes.
It has been designed to be installed also on the machine.
Warning:
adhere closely to the following advice
- Install in such a way that there is always adequate heat disposal.
- Always follow the Wiring Diagram on page 5 when making connections.
- All technical interventions must be performed with the engine stationary and terminal 50 of the starter
motor disconnected.
- Check that the line loading and the consumption of the connected equipment are compatible
with the described technical characteristics described on page 2.
- Always install under other equipment which produces or spreads heat.
- Never use a battery charger for the emergency start-up, the control unit could be damaged.
- In order to safeguard people and equipment, before connecting an external battery charger, disconnect
the electrical system terminals from the battery poles.
- Never disconnect the battery terminals with the motor pump running.
THIS CONTROL UNIT IS NOT SUITABLE FOR OPERATING IN THE FOLLOWING CONDITIONS:
- Where the environmental temperature is outside the limits indicated in the Technical Data on page 2.
- Where there are high levels or heat from radiation caused by the sun, ovens or the like.
- Where there is the risk of re or explosions.
- Where the control unit can receive strong vibrations or knocks.
ELECTROMAGNETIC COMPATIBILITY
This control unit functions correctly only if inserted in plants which conform with the CE marking standards;
it meets the exemption requirements of the standard EN61326-1 but it cannot be excluded that
malfunctions could occur in extreme cases due to particular situations.
The installer has the task of checking that the disturbance levels are within the requirements of
the standards.
CONDUCTION AND MAINTENANCE
The following maintenance operations should be performed every week:
- check that the indicators function;
- check the batteries;
- check that the conductors are tight, check the condition of the terminals.
UNLESS WE MAKE A WRITTEN DECLARATION STATING THE CONTRARY, THIS CONTROL UNIT IS
NOT SUITABLE FOR USE AS A CRITICAL COMPONENT IN EQUIPMENT OR PLANTS RESPONSIBLE
FOR KEEPING PERSONS OR OTHER LIVING BEINGS ALIVE.
NOTICES

ELCOS SRL - Parma - EN - CEM-380 /1
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ACCESSORIES ON REQUEST
RADIATOR COOLANT LEVEL PROBE
ROD ELECTRODE (complete with: rivet connection, bolt, nut, washer,
seal and female connector)
type AST-015/00 code 40241012
ORDERING DATA
- Type CEM-380 cod. 00210731
ACCESSORIES KIT
- Pre-wired female connector
type CEM-380 cod.70804417
kit rods CEP-CEM cod.40804362
- Pump water pressure
transmitter TYPE TPA-200 “ 70500255
- Nipple F1/4”
GAS -M3/8”GAS “ 70190241
SCREW ELECTRODE
(complete with lugs)
type E-25 code 40190115
SUPPORT FOR INSTALLATION
ON BASE
type CRU-003 code 40493384